Modular post-tensioned overlapped staggered building construction



March 31, 1970 s. w. SHELLEY 5 SheetsSheet 1 Filed Aug. 14, 1968 F l G.

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S. W. SHELLEY March 31, 1970 MODULAR POST-TENSIONED OVERLAPPED STAGGERED BUILDING CONSTRUCTION 5 Sheets-Sheet 2 Filed Aug. 14, 1968 FIG. 3

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INVENTOR SHELLEY W SHELLEY BY 447 flue-L ATTORNEY March 31, 1970 s. w. SHELLEY 3,503,170

MODULAR POST TENSIONED OVERLAPPED STAGGERED BUILDING CONSTRUCTION Filed Aug. 14, 1968 5 Sheets-Sheet 3 HIIHHHII E} 5/ F UIIHIIHHIII g g HIIIHIIII HlHIlIIIl l IHIIIIIIH g] lllllllllll! g? HIIIIIIHH IIIIIIIIIH Hllllllll HHIIIHIH llllllll cno INVENTOR SHELLEY w. SHELLEY "pH W ATTORNEY March 31, 1970 s. w. SHELLEY 3,503,170

MODULAR POST-TENSIONED OVERLAPPED STAGGERED BUILDING CONSTRUCTION Filed Aug. 14, 1968 5 Sheets-Sheet 4 INVENTOR SHELLEY w s LLEY Q4;

ATTORNEY March 31, 1970 s. w. SHELLEY 3,503,170

MODULAR POST-TENSIQNED OVERLAPPED STAGGERED BUILDING CONSTRUCTION 5 Sheets-Sheet 5 Filed Aug. 14. 1968 FIG. 7

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INVENTOR SHELLEY W SHELLEY (44 ATTORNEY United States Patent O 3,503,170 MODULAR POST-TENSIONED OVERLAPPED STAGGERED BUILDING CONSTRUCTION Shelley W. Shelley, 58 C St., Urb. Industrial Constitution, Puerto Nuevo, Isla Verde, Puerto Rico 00630 Filed Aug. 14, 1968, Ser. No. 762,668 Int. Cl. E04c 3/22, 5/08; E04h 1/348 US. Cl. 52-227 6 Claims ABSTRACT OF THE DISCLOSURE The present disclosure relates to a modular post-tensioned overlapped staggered building construction in which individual prefabricated three-dimensional boxlike units are first formed and then assembled at a distance between each other and overlapped and staggered in respect to each other so that between each four units additional living space is created, and shafts for reception of utilities. Desirably, the overlapping portions of the Wall are post-tensioned together to form a unitary building structure.

In forming the units, the walls and partitions are first pre-cast and then set in position for a secondary prefabrication procedure, according to which, after placing the walls in position, one fioor lab is cast to form a monolithic structure with the walls and partitions. Then, either in position or after inversion, the floor slab is cast to form a monolithic box structure with the walls and partitions and the floor.

The complete unit, including partitions and slabs, will form a beam structure in one or two directions, which will reduce the span of the slab from the total size of the box to the total sizes of the individual rooms.

DESCRIPTION OF THE INVENTION The present invention relates to a modulator posttensioned overlapped staggered building construction in which the units are preferably preformed or prefabricated of concrete, or light concrete, or a similar material.

It is among the objects of the present invention to form a prefabricated modular post-tensioned overlapped staggered building construction particularly designed for apartments but also useful for ofiice buildings or other structures, in which a plurality of prefabricated units may be readily assembled together and in which the utilities will be part of the pre-assembly and can afterwards be connected together in the final assembled structure.

Another object is to provide a modular post-tensioned overlapped staggered building construction in which the units are staggered in respect to each other so that they will have open areas in between which can also be utilized and/or converted into additional living space, work space or space for other purposes.

Another object is to provide a modular post-tensioned overlapped staggered building construction in which the units are assembled together by means of corner columns or intermediate columns or both, as for example by post-tensioning arrangements which will form a permanent connection between the units.

A further object is to provide a prefabricated building unit which will be made entirely out of pre-cast elements and in which the outside walls and inside walls, floor and ceiling may be assembled together into a single unit where the floor and ceiling slabs and partitions and walls are connected together by reenforcing rods and/or posttensioning cables through the partitions to form economical prefabricated structural units to be assembled into the building structure.

A still further object is to provide a modular post-tensioned overlapped staggered building construction in which the utilities, including electricity, gas, water, sewage and the like are all assembled in a predetermined location as part of the pre-cast unit, ready for assembly into the final building structure.

Still further objects and advantages will appear in the more detailed description set forth below, it being understood, however, that this more detailed description is not given by way of limitation, since various changes therein may be made by those skilled in the art Without departing from the scope and spirit of the present inven tion.

In accomplishing the above objects, it has been found most suitable to form an elongated rectangular boxlike unit, in which the side walls, floor and ceiling are formed of concrete and in which the front and back or intermediate walls may also be formed of concrete or of other materials, after assembly.

In the preferred construction, the outside walls are provided with a series of inwardly or outwardly projecting columns having central openings through which posttensioning ca'bles may be extended at the end of the assembly. For example, normally a certain number of floors may be provided and the post-tensioning cables may be used, and this can be followed by other successive series of units in which the post-tensioning cables may be em ployed.

In the desired units, the rear or front of the structure or both may be provided with a corridor or walkway, which may communicate with an elevator structure or staircase. This corridor or Walk-way may be supported by cantilever beams projecting from the columns or walls of the prefabricated box or boxes or boxlike structures.

In forming these pre-cast concrete structures, the exterior walls, and also if desired the interior Walls, may be first formed and placed upon a base upon which the floor or ceiling may be cast afterwards. It is after this structure is formed that the partial unit may be turned over and the missing floor or ceiling then be cast so as to form the integral unit. Desirably, one unit will consist of end bedrooms with an intervening bath, and normally the free space between the basic units may be formed into a dining and living space, with the kitchen being at one side of the unit and immediately adjacent the alcove for carrying the kitchen cabinet and utilities, so that the kitchen cabinet and bath unit will be adjacent at one end to the shaft carrying the piping and other utilities.

Alternately the kitchen enclosure can be in the free space adjoining the utility shaft for easy connection of the utilities.

The free space or the box unit may contain a balcony, either externally projecting or internally projecting of the structure.

Alternate boxlike units might have a cantilever, front or back, to increase the apartment space.

End units must be provided With special pre-cast units which might receive kitchen and/ or libraries and/ or closet facilities.

Where air conditioning is to be employed, conduits can be provided through the utility shaft and other areas, and false ceilings may be employed.

In the preferred design, the bath unit is generally adjacent to the kitchen facilities so that both may use common utility lines.

The open spaces of the uppermost floor may have special pre-cast ceilings, for example of flat or U-shaped cross-section structure, to cover them.

BRIEF DESCRIPTION OF DRAWINGS With the foregoing and other objects in view, the invention consiste of the novel construction, combination andarrangernent of parts as hereinafter more specifically described, and illustrated in the accompanying drawings, wherein is shown an embodiment of the invention, but it is to be understood that changes, variations and modifications can be resorted to which fall within the scope of the claims hereunto appended.

In the drawings wherein like reference characters denote corresponding parts throughout the several views:

FIG. 1 is a diagrammatic front perspective view show ing the assembly of the boxlike modular overlapping units as they have been placed in position to form a complet building structure.

FIG. 2 is a horizontal transverse sectional view illustrating one living unit, upon an enlarged scale as compared to FIG. 1.

FIG. 3 is a transverse diagrammatic sectional view showing the post-tensioning cable extending between two overlapped portions of superimposed building units, upon an enlarged scale as compared to FIGS. 1 and 2.

FIG. 4 is a fragmentary transverse sectional view showing the utility column or shaft between two overlapped building units, upon an enlarged scale as compared to FIGS. 1 and 2.

FIG. 5 is a front elevation of a typical post-tensioned overlapping modular arrangement, upon about the same scale as FIG. 1.

FIG. 6 is a diagrammatic transverse sectional view showing the cable extending through a foundation slab, a single boxlike unit, as well as the ceiling slab, and being attached at its lower and upper ends, upon an enlarged scale as compared to FIGS. 1, 2 and 5.

FIG. 7 is similar to FIG. 2 but eliminating the various interior additions to the modular construction.

FIG. 8 is a diagrammatic vertical transverse sectional view showing the connection between upper and lower slabs of a single unit through the interior partitions.

Referring to FIG. 1, there is shown a series of preassembled pre-formed modular units A which are overlapped at B. The interspaces C, which are shown open in FIG. 1, may receive additional living space upon being closed off at their front and back. The interspaces at the base are prefereably provided with overlapping base slabs D, either cast in place or prefabricated and overlapping under the adjacent boxlike units A. The overhanging units A may be provided with connecting columns E, which may be replaced by walls. The units A as shown in FIG. 1 are provided with the end windows or openings F.

Referring to the diagrammatic horizontal transverse sectional view of a typical unit as shown in FIG. 2, there are shown the units A, each of which are provided with the side walls and 21 and the interior partitions 22, 23 and 24 extending from front to back, and the transverse partitions 25, 26, 27 and 28. The width of the unit extends from and between the side walls 20 and 21, as indicated by the arrowed line 29, and there are provided vertical enlargements or columns 30, 31, 32, 33, 34, 35, 36 and 37, which may receive post-tensioning cables.

In the plan shown, there is also provided a utility column or receptacle 46 which will receive the water, sewage, electricity, air conditioning, gas and other utilities. The interior may have the front bedrooms 38 and 39, the rear bedroom 40, the bathroom 41 having the washbasin 42, the bath or shower 43, and the toilet 44. These are connected to the utility shaft 46, both for entrance of water and disposal of sewage.

Between the units A are the interspaces C, which may receive the kitchen 50 having the sink 51, kitchen cabinet and stove 52, table 53 and refrigerator 54. In the unit as.

shown closetsmay be provided at 55 and '56, 57, 58 and 59. It will be noted that the side wall 20 has no openings therein but that the side wall 21 has openings at 60 to communicate with the kitchen 50 and at 61 to communicate with the living room 62. The utility room 63 may communicate with the kitchen through the Opening 60 in a 4 the wall 21. A laundry or other washing machine may be placed at 64 in the utility room 63.

As shown in FIG. 2, the front of the living room 62 may be provided with the folding doors 70 and the flower boxes 71 upon the balcony 72. The rear of the unit of FIG. 2 may have a walk-way or corridor 73 extending to elevators or stairs at the end of the unit (not shown). This walk-way or corridor may be supported from the columns 30 and 34-by cantilevers or other structures.

In FIG. 3 there is shown the overlapping corners of an upper unit and 81 of a lower unit which are at the lower end of the column 82 and at the upper end of co umn 83, with the floor slab 84 directly connected to the column 82 in the upper unit A and the floor slab 85 directly connected to the column 83 in the lower unit A.

The space 86 between the corners may be sealed by means of grouting or other sealing materials. Interiorly the units are held together by one or more cables 87, which extend through the space 88. The space 88 is grouted after the cable or cables have been tensioned in position.

This cable may extend through all of the units vertically fromthe ground to the top or it may extend through a series of units.

Referring to FIG. 4, there is shown the utility shaft 90, which is enclosed in an opening formed between the outside wall 91 and the inside partition 93. For the upper box or module the utility shaft is positioned between the outside wall 92 and the inside wall 94. These are shown in FIG. 4 as being prefabricated and formed unitarily with the floor or ceiling structure 95 and 96. They also may be fabricated separately of asbestos, cement or other material or by removable panels to allow access for repairs.

The space 97 is grouted or otherwise sealed with suitable material. There are shown illustratively various pipes 98 and 99 for conducting water, sewage, or other utility purposes. The openings 100 and 101 are in the floor and ceiling, and permit communication from one unit to another. The utilities may be placed in position, together with the units and connected from one unit to the next upper or lower unit thereof, or they may be placed in after the overlapping units have been assembled. The pipes are usually in a straight line and suflicient space is provided to permit whatever utilities are necessary, and considerable connections are made to the kitchen and bathroom in each unit.

In FIG. 5, there is shown a diagrammatic front eleva- .tional view of a series of units A assembled together with the overlapping portions B, the windows F and the balcony railings G. There is shown a section of the ground at but this may be replaced by slabs extending over the entire area or only under the open spaces C.

FIG. 7 represents the structural unit only and it does not show the various appliances and other additions such as are indicated in FIG. 2. In FIG. 7 the columns 30 through 37 may all be post-tensioned by cables, such as indicated at 87 in FIG. 3, and the utility receptacle 46 may consist of an opening extending through the various units vertically, part or all of which may match the opening in the next lower unit at the overlap, so that straight pipesand conduits may extend the entire length of the building. I r

Interiorly there also are provided, in connection with the enlargements in the thickness of the partitions, as indicated at 111, 112, 113 and 114, through which tensioned cables or rods may be extended for the purpose of tying the floor and ceiling slabs, together with the partitions, into a single structural unit.

In FIG. Sis shown a unit such as FIG. 7, with a ceiling 115, a floor 116 and-the vertical partitions 117 and 118, or enlargements upon such partitions through which may be extended the rods or tensioning cables 119 and 120,-

which may be mounted in position by means of the reinforcements 121 and 122. At the top, as indicated at 123 and 124, there is shown location of suitable securing means, particularly in case of cables. As indicated at the left of FIG. 8, the ceiling 115 is shown as having an extension 125 and a guard rail 126 for the walk-way on the outside of the structure. In FIG. 8 there are shown a Wall 128 and a window 127 and 129.

In FIG. 6, the post-tensioned cable 140 is mounted by means of the securing plates 141 and 142 and a securing device 143 in the opening 144 in the footing structure 145. This footing structure may be buried in the ground and may extend upwardly to a point 146 directly below the floor slab 147. This floor slab may be positioned directly below the open spaces 148 between the modular unit 149 of the ground floor. The upper modular unit is indicated at 150 and it will have a top slab 151 over the space between the modular unit of the uppermost floor.

The broken space as indicated at 152 indicates that any number of modular units may be positioned between the lowermost unit 149 and the uppermost unit 150. The top slab 151 will be provided with a recess 153 receiving the plates 154 and 155 and the securing device 156 for the top of the post-tensioning cable 140. The recess 153 is then filled in with grout or other suitable material. The spaces indicated at 158, 159, 160 and 161 may also be filled with grout.

As shown, the walls and partitions such as indicated at 20, 21, 22 and 23 in FIG. 2 may be pre-cast, preferably horizontally, and then placed vertically in position in a second pre-cast setting and connected by a lower slab and thereafter in place, pre-cast by an upper slab which will respectively serve as floors and ceilings. The slabs are preferably poured in place so that the unit, as indicated in FIG. 2 or in FIGS. 7 and 8, may be assembled in the building structure of FIGS. 1 and 5. The post-tensioning indicated by the cable 140 in FIG. 6 or 87 in FIG. 3 may be accomplished after the units have been assembled.

Thus all the boxes or units A will be unitarily assembled together with the overlapping portions B being highly compressed. In addition, as indicated in FIGS. 7 and 8, the walls and partitions of each unit may be vertically provided with reinforcing tensioning cables or rods, indicated at 119 and 120 in FIG. 8. These units, being assembled in this way, will act both vertically and horizontally as beam structures in view of the monolithic structure of both floor and ceiling slabs tied together and the vertical walls and partitions sandwiched therebetween.

The structure design is particularly resistant to earthquakes because of the high rigidity of the individual boxes and modular units and at the same time because of the flexibility of the entire structure, due to the overlap staggered system of post-tensioning cables where each unit is post-tensioned not between two other units but between four other units on the four corners thereof.

In forming the shaft openings 90 and 89, as indicated in FIG. 4, it will be noted that the openings only partially overlap in the superimposed units, and the extra space 150 and 151 is used for access or for repair purposes. To achieve this overlapping of the spaces 89 and 90, the units of FIGS. 2 and 7 are made mirror images for alternate floors, so that one mirror image will be superimposed above another mirror image and there will be one shaft for every second vertical wall in the connection between boxlike units. In other words, although the posttensioning cables may extend through every overlapping wall, the shaft for utilities extends through only every second overlapping wall.

By overlapping so that the overlap extends substantially beyond the thickness of the walls, there is a sufficient overlap to provide space for the utility shaft and the columns are located one upon the other.

As many changes could be made in the above modular post-tensioned overlapped staggered building construction, and many widely different embodiments of this invention could be made without departure from the scope of the claims, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.

Having now particularly described and ascertained the nature of the invention, and in what manner the same is to be performed, what is claimed is:

1. A modular post-tensioned overlapping staggered building structure composed of a plurality of box-like units, said units having side walls and interior partitions and ceiling and floor slabs pre-cast as a single unit, said units overlapping at the sides thereof and provided with vertical columns superimposed upon one another, and post-tensioning means extending through said columns vertically from the lowest to the uppermost of said boxlike units, said boxes being positioned so that there will be an open space between each two boxlike units alongside each other, with upper and lower boxlike units covering said open spaces, and each boxlike unit being posttensioned between four other units.

2. The structure of claim 1, in which the post-tensioning means extend through the sides of alternate staggered overlapping boxlike units extending in opposite directions.

3. The structure of claim 1, in which each plan of each boxlike unit in the floor is a mirror image of the plan of the boxlike unit in the next upper and lower floor.

4. The structure of claim 1, in which an open shaft for utilities extends vertically through the overlapping portions of each boxlike unit.

5. The structure of claim 1, in which the post-tensioning means extend through the sides of alternate staggered overlapping boxlike units extending in opposite directions and partition walls also carrying post-tensioning means.

6. The structure of claim 1, in which the post-tensioning means extend through the sides of alternate staggerd overlapping boxlike units extending in opposite directions and interior partitions devoid of post-tensioning means.

References Cited UNITED STATES PATENTS 1,797,813 3/1931 Williams et al. 52663 3,226,894 1/1966 Burchard et al. 52-185 FOREIGN PATENTS 1,226,605 2/1960 France. 1,232,626 4/1960 France. 1,270,441 7/ 1961 France.

50,745 5/ 1966 Germany. 216,721 1/1961 Austria.

FRANK L. ABBOTT, Primary Examiner J. L. RIDGILL, JR., Assistant Examiner US. Cl. X.R. 5279, 236, 745 

